Disc brake device

ABSTRACT

A disc brake device in which a moment acts on a pad in a direction in which a rotation-in side portion is pushed up toward a radially outer side during braking, including the pad including a pin insertion portion and a clip insertion portion, a pad support member, including a pin inserted into the pin insertion portion in an axial direction, and supporting the pad so that the pad is movable in the axial direction, and a pad clip, including a pad pressing portion inserted into the clip insertion portion in the axial direction, and configured to press the pad radially outward. The pad clip is configured to apply a pressing force to the pad so that a radially inner side portion of an inner peripheral surface of the pin insertion portion is pressed against a radially inner side portion of the pin.

CROSS-REFERENCE TO RELATED APPLICATIONS

The disclosure of Japanese Patent Application No. 2020-134920 filed on Aug. 7, 2020, including specification, drawings and claims is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present invention relates to a disc brake device.

BACKGROUND ART

A disc brake device obtains a braking force by pressing a pad, which is supported by a pad support member so as to be movable in an axial direction, against a side surface of a rotor in the axial direction. In such a disc brake device, various structures have been proposed in related-art as a pad support structure for supporting the pad so as to be movable in the axial direction with respect to the pad support member.

FIGS. 19 and 20 show a disc brake device 1 having a related-art structure including a pad support structure using a pin, which is disclosed in Patent Literature 1. The disc brake device 1 is an opposed piston type disc brake device, and includes a caliper 2 serving as a pad support member, an inner pad 3 and an outer pad 4.

The caliper 2 supports the inner pad 3 and the outer pad 4 so as to be movable in an axial direction (an upper-lower direction in FIG. 19, a front-back direction in FIG. 20). The caliper 2 includes an inner body 6 and an outer body 7 that are disposed on both sides of a rotor 5 in the axial direction, a first coupling portion 8, a second coupling portion 9 and a third coupling portion 10 that each couple the inner body 6 and the outer body 7 in the axial direction, and a pair of pins 11 a, 11 b that are bridged between the inner body 6 and the outer body 7.

In the disc brake device 1, the axial direction, a circumferential direction and a radial direction refer to an axial direction, a circumferential direction and a radial direction of the rotor 5 unless otherwise specified.

Each of the inner body 6 and the outer body 7 has overhanging wall portions 12 a, 12 b overhanging toward the rotor 5 in the axial direction at both side portions in the circumferential direction. The overhanging wall portions 12 a, 12 b respectively include flat surface-shaped torque receiving surfaces 13 a, 13 b on side surfaces in the circumferential direction, the side surfaces facing each other in the circumferential direction. The first coupling portion 8 and the second coupling portion 9 each couple end portions of the inner body 6 and the outer body 7 in the circumferential direction to each other in the axial direction, and the third coupling portion 10 couples intermediate portions of the inner body 6 and the outer body 7 in the circumferential direction to each other in the axial direction. The first coupling portion 8 and the second coupling portion 9 respectively include flat surface shaped moment bearing surfaces 14 a, 14 b on side surfaces in the circumferential direction, the side surfaces facing the third coupling portion 10 in the circumferential direction. Each of the inner body 6 and the outer body 7 includes cylinders, and pistons are respectively fitted in the cylinders so as to be movable in the axial direction.

Each of the pair of pins 11 a, 11 b has a cylindrical shape and is disposed parallel to a central axis of the rotor 5. End portions of the pair of pins 11 a, 11 b in the axial direction are each supported by radially outer side portions of the inner body 6 and the outer body 7. Therefore, the pair of pins 11 a, 11 b are bridged between the inner body 6 and the outer body 7.

Each of the inner pad 3 and the outer pad 4 includes a lining 15 and a back plate 16 supporting a back surface of the lining 15. The back plate 16 includes pin insertion portions 17 a, 17 b at two positions separated from each other in the circumferential direction at a radially outer side portion. Each of the pin insertion portions 17 a, 17 b is a through hole penetrating in the axial direction. In a shown example, each of the pin insertion portions 17 a, 17 b has an elliptical shape. A radial width dimension and a circumferential width dimension of each of the pin insertion portions 17 a, 17 b are larger than an outer diameter of each of the pins 11 a, 11 b.

The back plate 16 has torque transmission surfaces 18 a, 18 b and moment transmission surfaces 19 a, 19 b respectively on both side surfaces in the circumferential direction. The torque transmission surfaces 18 a, 18 b are respectively provided on radially inner side portions of the side surfaces of the back plate 16 in the circumferential direction. The moment transmission surfaces 19 a, 19 b are respectively provided on radially outer side portions of the side surfaces of the back plate 16 in the circumferential direction.

In the pair of pin insertion portions 17 a, 17 b, one pin 11 a disposed on one side in the circumferential direction is inserted in the axial direction into one pin insertion portion 17 a disposed on the one side in the circumferential direction (a rotation-in side when moving forward), and the other pin 11 b disposed on the other side in the circumferential direction is inserted in the axial direction into the other pin insertion portion 17 b disposed on the other side in the circumferential direction (a rotation-out side when moving forward). Thereby, the inner pad 3 and the outer pad 4 are supported by the caliper 2 so as to be movable in the axial direction by using the pair of pins 11 a, 11 b.

The disc brake device 1 further includes a pad clip 20 in order to prevent rattling of the inner pad 3 and the outer pad 4 during non-braking. The pad clip 20 is made of a metal plate and includes a substrate portion 21, a pair of first pad pressing portions 22 a, 22 b, a pair of second pad pressing portions 23 a, 23 b, a first pin pressing portion 24, and a second pin pressing portion 25.

The substrate portion 21 is disposed at an intermediate portion of the pad clip 20 in the circumferential direction. The pair of first pad pressing portions 22 a, 22 b are disposed on one side portion of the pad clip 20 in the circumferential direction so as to be separated from each other in the axial direction, and extend in the circumferential direction from an end portion of the substrate portion 21 on the one side in the circumferential direction. The pair of second pad pressing portions 23 a, 23 b are disposed on the other side portion of the pad clip 20 in the circumferential direction so as to be separated from each other in the axial direction, and extend in the circumferential direction from an end portion of the substrate portion 21 on the other side in the circumferential direction. The first pin pressing portion 24 is disposed between the first pad pressing portions 22 a, 22 b, and extends in the circumferential direction from the end portion of the substrate portion 21 on the one side in the circumferential direction. The second pin pressing portion 25 is disposed between the second pad pressing portions 23 a, 23 b, and extends in the circumferential direction from the end portion of the substrate portion 21 on the other side in the circumferential direction.

In a mounted state of the pad clip 20, the substrate portion 21 is disposed on a radially inner side of the third coupling portion 10. The first pin pressing portion 24 pushes up the pin 11 a on the one side in the circumferential direction toward a radially outer side, and the pair of first pad pressing portions 22 a, 22 b press one side portion of an outer peripheral edge portion of each of the inner pad 3 and the outer pad 4 in the circumferential direction toward a radially inner side. The second pin pressing portion 25 pushes up the pin 11 b on the other side in the circumferential direction toward the radially outer side, and the pair of second pad pressing portions 23 a, 23 b press the other side portion of the outer peripheral edge portion of each of the inner pad 3 and the outer pad 4 in the circumferential direction toward the radially inner side.

Thereby, a posture of each of the inner pad 3 and the outer pad 4 is stabilized, and occurrence of a rattling noise (an abnormal noise) due to rattling of the inner pad 3 and the outer pad 4 during non-braking is prevented. In the disc brake device 1 having the related-art structure, radially outer side portions of inner peripheral surfaces of the pin insertion portions 17 a, 17 b are respectively pressed against radially outer side end portions of the pins 11 a, 11 b by pressing forces of the pad clip 20. Therefore, a gap is formed between a radially inner side portion of the inner peripheral surface of each of the pin insertion portions 17 a, 17 b and a radially inner side end portion of each of the pins 11 a, 11 b.

The pad clip 20 presses the pin 11 b on the other side in the circumferential direction toward the one side in the circumferential direction by a third pin pressing portion 26 provided at a tip end portion of the second pin pressing portion 25. Thereby, each of the inner pad 3 and the outer pad 4 is pressed toward the other side in the circumferential direction by using a third pad pressing portion 27 provided at tip end portions of the first pad pressing portions 22 a, 22 b. The torque transmission surface 18 b provided on a side surface of each of the inner pad 3 and the outer pad 4 on the other side in the circumferential direction is brought into contact with the torque receiving surface 13 b provided on each of the inner body 6 and the outer body 7. Thereby, during forward braking, the torque transmission surface 18 b and the torque receiving surface 13 b are prevented from vigorously colliding with each other to cause an abnormal noise.

Patent Literature 1: JP-A-2011-163444

SUMMARY OF INVENTION

A disc brake device in which a moment acts on a pad in a direction in which a rotation-in side portion is pushed up toward a radially outer side during braking, according to the present invention includes the pad, a pad support member and a pad clip.

The pad includes a pin insertion portion and a clip insertion portion.

The pad support member includes a pin inserted into the pin insertion portion in an axial direction and supports the pad so that the pad movable in the axial direction.

The pad clip includes a pad pressing portion inserted into the clip insertion portion in the axial direction and presses the pad radially outward.

In the disc brake device according to the present invention, the pad clip is configured to apply a pressing force to the pad so that a radially inner side portion of an inner peripheral surface of the pin insertion portion is pressed against a radially inner side portion of the pin

In the present invention, at least during forward braking, the moment can act on the pad in the direction in which the rotation-in side portion is pushed up toward the radially outer side and the rotation-out side portion is pushed down toward the radially inner side. Preferably, both during forward braking and reverse braking, the moment can act on the pad in the direction in which the rotation-in side portion (a rotation-in side portion when moving forward and a rotation-in side portion when moving reversely) is pushed up toward the radially outer side and the rotation-out side portion (a rotation-out side portion when moving forward and a rotation-out side portion when moving reversely) is pushed down toward the radially inner side.

In the disc brake device according to one aspect of the present invention, the pad clip may be elastically deformed between the pad and the pin to apply a pressing force radially outward to the pad.

Alternatively, the pad clip may be elastically deformed between the pad and a portion of the pad support member other than the pin or another member to apply the pressing force radially outward to the pad. For example, when the disc brake device according to the present invention is applied to an opposed piston type disc brake device, the pad clip may be disposed between the pad and an inner body, an outer body or a coupling portion constituting a caliper serving as the pad support member while being elastically deformed. In addition, when the disc brake device according to the present invention is applied to a floating type disc brake device, the pad clip may be disposed between the pad and a support serving as the pad support member while being elastically deformed.

In the disc brake device according to one aspect of the present invention, the present invention may be applied to an opposed piston type disc brake device, and the pad support member may be a caliper having an inner body and an outer body disposed with a rotor sandwiched therebetween.

In this case, the pad support member may have a torque receiving surface at a radially inner side portion of a rotation-out-side portion and a moment bearing surface at a radially outer side portion thereof, supports a tangential force acting on the pad during braking by the torque receiving surface, and supports the moment acting in the direction in which the rotation-in-side portion of the pad is pushed up toward the radially outer side on the pad during braking by the moment bearing surface.

Alternatively, in the disc brake device according to one aspect of the present invention, the present invention may be applied to a floating type disc brake device, and the pad support member may be a support.

In this case, the pad support member may have, on each of circumferential side surfaces facing each other in the circumferential direction, an engagement recess capable of being engaged with an ear portion provided in the pad so as to be movable in the axial direction, and may have a torque receiving surface at a portion on a radially inner side of the engagement recess in the circumferential side surface on the rotation-out side, and a moment bearing surface on a side surface on a radially outer side in an inner surface of the engagement recess on the rotation-in side.

In the disc brake device according to one aspect of the present invention, a pair of the pads may be provided. In this case, the pair of pads may be the same components.

Alternatively, the pair of pads may be separate components having shapes different from each other (for example, at positions where the clip insertion portions are formed).

In the disc brake device according to one aspect of the present invention, the pad may include the clip insertion portion at a central portion of a radially outer side portion in a circumferential direction.

In the disc brake device according to one aspect of the present invention, the pad may have a pair of the pin insertion portions on both sides of the radially outer side portion in the circumferential direction so as to sandwich the clip insertion portion, and the pad support member may include a pair of the pins inserted into the pair of pin insertion portions, respectively.

Alternatively, the pad may have the pin insertion portion only on the rotation-in side or the rotation-out side of the clip insertion portion, and the pad support member may have only one pin.

In the disc brake device according to one aspect of the present invention, the pad clip may be made of a metal plate and may include a substrate portion having the pad pressing portion at an end portion in the axial direction and a pair of circumferential arm portions extending from the substrate portion in directions away from each other in the circumferential direction, and each of the pair of circumferential arm portions may include a pin pressing portion (an anchor portion) disposed on a radially outer side of the pin and configured to press the pin radially inner side.

Alternatively, the pad clip may be made of a metal wire.

Alternatively, each of the pair of circumferential arm portions may be a pin pulling portion disposed on a radially inner side of the pin and configured to pull the pin radially inward.

In the disc brake device according to one aspect of the present invention, the pad clip may further press the pair of pins in directions opposite to each other in the circumferential direction.

In the disc brake device according to one aspect of the present invention, the circumferential arm portion may have a corrugated shape undulating in a radial direction.

In this case, the circumferential arm portion may include, between the substrate portion and the pin pressing portion, a first curved portion curved so as to be convex on a radially inner side, a second curved portion curved so as to be convex on a radially outer side, and a third curved portion curved so as to be convex on a radially inner side, in this order from the substrate portion.

Further, in this case, in a free state of the pad clip, a circumferential interval between side surfaces of the pair of third curved portions on sides far from each other in the circumferential direction may be larger than a circumferential interval between end portions of the pair of pins on sides close to each other in the circumferential direction.

In the disc brake device according to one aspect of the present invention, the circumferential arm portion may further include a tapered portion whose axial width decreases as being away from the substrate portion in the circumferential direction.

In the disc brake device according to one aspect of the present invention, the pair of pads may be provided, the pad clip may have a substantially cross shape as viewed in the radial direction, and the substrate portion may include a pair of the pad pressing portions disposed at the end portions on both sides in the axial direction and respectively inserted into the clip insertion portions provided in the pair of pads.

In the disc brake device according to one aspect of the present invention, the pad clip may include an axial member having the substrate portion and extending in the axial direction, and a circumferential member formed separately from the axial member, having the pair of circumferential arm portions and extending in the circumferential direction.

In this case, the axial member and the circumferential member can be fixed by caulking or riveting.

In the disc brake device according to one aspect of the present invention, the pad pressing portion may have, on a radially outer side end surface thereof, a flat surface-shaped pressing surface configured to be in surface contact with a radially outer side portion of an inner peripheral surface of the clip insertion portion.

Alternatively, the pad pressing portion may have, on the radially outer side end surface thereof, a convex curved surface-shaped pressing surface configured to be in line contact with the radially outer side portion of the inner peripheral surface of the clip insertion portion.

In the disc brake device according to one aspect of the present invention, the pad pressing portion may be inclined in a direction radially inward as being away from the rotor in the axial direction, and presses the pad radially outward and in a direction away from the rotor in the axial direction.

Alternatively, the pad pressing portion may be disposed parallel to a central axis of the rotor.

The disc brake device according to one aspect of the present invention may further include a circumferential clip configured to be elastically deformed between the pad and the pad support member and presses the pad and the pad support member in directions opposite to each other in the circumferential direction.

In this case, a pair of the circumferential clips may be provided, and one circumferential clip may press the pad toward one side in the circumferential direction, and the other circumferential clip may press the pad toward the other side in the circumferential direction.

A radially inner side portion of the pad may be pressed by the circumferential clip.

The circumferential clip may be fixed to the pad.

The circumferential clip may press portions of the pad and the pad support member, the portions having radial positions being the same as that of a radially inner end edge of a lining included in the pad, or portions of the pad and the pad support member, the portions being located radially inward than the radially inner end edge of the lining.

In the disc brake device according to one aspect of the present invention, the pin insertion portion may be a through hole that opens only on both sides of the pad in the axial direction, or may be a notch that opens on both sides of the pad in the axial direction and other portions.

In the disc brake device according to one aspect of the present invention, the clip insertion portion may be a through hole that opens only on both sides of the pad in the axial direction, or may be a notch that opens on both sides of the pad in the axial direction and other portions. Further, the clip insertion portion may be a bottomed hole that opens only on one side (a rotor side) in the axial direction of the pad.

Advantageous Effects of Invention

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a front view showing a disc brake device according to a first embodiment.

FIG. 2 is a plan view showing the disc brake device according to the first embodiment.

FIG. 3 is a side view showing the disc brake device according to the first embodiment.

FIG. 4 is a perspective view of the disc brake device according to the first embodiment as viewed from the front side, a radially outer side and a circumferentially other side.

FIG. 5 is a cross-sectional view taken along a line A-A in FIG. 2.

FIG. 6 is an enlarged view of a portion B in FIG. 5.

FIG. 7 is an enlarged view of a portion C in FIG. 5.

FIG. 8 is an enlarged view of a portion D in FIG. 5.

FIG. 9 is a front view showing an inner pad (an outer pad) taken out from the disc brake device according to the first embodiment.

FIG. 10 is a rear view showing the inner pad (the outer pad) taken out from the disc brake device according to the first embodiment.

FIG. 11 is a side view showing the inner pad (the outer pad) taken out from the disc brake device according to the first embodiment.

FIG. 12A is a front view showing the inner pad (the outer pad) before a circumferential clip is fixed.

FIG. 12B is a rear view showing the inner pad (the outer pad) before a circumferential clip is fixed.

FIG. 13 is a front view showing the pad clip taken out from the disc brake device according to the first embodiment.

FIG. 14 is a plan view showing the pad clip taken out from the disc brake device according to the first embodiment.

FIG. 15 is a side view showing the pad clip taken out from the disc brake device according to the first embodiment.

FIGS. 16A, 16B, 16C are schematic views for explaining an assembly process of the disc brake device according to the first embodiment.

FIG. 17 is a view corresponding to FIG. 14, showing a second embodiment.

FIG. 18 is a view corresponding to FIG. 15, showing a third embodiment.

FIG. 19 is a plan view showing a disc brake device having a related-art structure.

FIG. 20 is a cross-sectional view taken along a line E-E in FIG. 19.

DESCRIPTION OF EMBODIMENTS

In the disc brake device 1 having the related-art structure, the posture of each of the inner pad 3 and the outer pad 4 is unstable during so-called light braking in which brake fluid has a low hydraulic pressure and a pressing force of the lining 15 against the rotor 5 is reduced, for example, at the time of switching between forward and reverse movement in a parking lot or during deceleration traveling, and thus a brake noise may occur.

That is, in the disc brake device 1, as shown in FIG. 20, during forward braking, a brake tangential force F1 directed to the other side in the circumferential direction (a left side in FIG. 20 and the rotation-out side when moving forward) acts on a point A at a friction surface center of the lining 15 constituting the inner pad 3 (the outer pad 4). Then, the brake tangential force F1 is supported by an abutting portion between the torque transmission surface 18 b and the torque receiving surface 13 b that are disposed radially inward than a line of action of the brake tangential force F1. Therefore, during forward braking, a moment M1 that attempts to rotate the inner pad 3 (the outer pad 4) counterclockwise acts on the inner pad 3 (the outer pad 4).

The moment M1 is supported by rotating the inner pad 3 (the outer pad 4) counterclockwise and bringing the moment transmission surface 19 b disposed on the other side in the circumferential direction into abutting the moment bearing surface 14 b. However, since the moment M1 acting on the inner pad 3 (the outer pad 4) is small during light braking, it is difficult to bring the moment transmission surface 19 b into abutting the moment bearing surface 14 b against an elastic force of the pad clip 20.

Specifically, when the moment M1 is reduced, the first pad pressing portion 22 a (22 b) overcomes a force of pressing the outer peripheral edge portion of the inner pad 3 (the outer pad 4) toward the radially inner side, and it is difficult to rotate the inner pad 3 (the outer pad 4) counterclockwise. Therefore, the moment transmission surface 19 b and the moment bearing surface 14 b are separated from each other, and the posture of the inner pad 3 (the outer pad 4) is unstable. As a result, the brake noise is likely to occur. Such a problem of the brake noise occurs not only during forward braking but also during reverse braking.

The present invention has been made to solve the above problems, and an object thereof is to provide a disc brake device capable of preventing occurrence of a brake noise even during light braking.

First Embodiment

A first embodiment will be described with reference to FIGS. 1 to 16C.

[Overall Configuration of Disc Brake Device]

A disc brake device 1 a according to the present embodiment is an opposed piston type disc brake device used for braking an automobile, and includes a caliper 2 a corresponding to a pad support member, an inner pad 3 a and an outer pad 4 a corresponding to pads, and a pad clip 20 a.

In the present embodiment, an axial direction, a circumferential direction and a radial direction refer to an axial direction, a circumferential direction and a radial direction of a disc-shaped rotor 5 that rotates together with wheels unless otherwise specified (see FIG. 2). A front-back direction in FIGS. 1, 5 to 10, 12A, 12B, 13 and 16A, 16B, 16C, an upper-lower direction in FIGS. 2 and 14, and a left-right direction in FIGS. 3, 11 and 15 correspond to the axial direction. A side close to the rotor 5 in the axial direction is referred as an axially inner side, and a side far from the rotor 5 in the axial direction is referred as an axially outer side. A left-right direction in FIGS. 1, 2, 5 to 10, 12A, 12B, 13, 14 and 16A, 16B, 16C, and a front-back direction in FIGS. 3, 11 and 15 correspond to the circumferential direction. A right side in FIGS. 1, 2, 5 to 9, 12A, 13, 14 and 16A, 16B, 16C, a left side in FIGS. 10 and 12B, and a front side in FIGS. 3 and 11 are referred to as one side in the circumferential direction, and a left side in FIGS. 1, 2, 5 to 9, 12A, 13, 14 and 16A, 16B, 16C, a right side in FIGS. 10 and 12B, and a back side in FIGS. 3 and 11 are referred to as the other side in the circumferential direction. In the present embodiment, the one side in the circumferential direction is a rotation-in side when a vehicle is moving forward and a rotation-out side when the vehicle is moving reversely, and the other side in the circumferential direction is a rotation-out side when the vehicle is moving forward and a rotation-in side when the vehicle is moving reversely. An upper-lower direction in FIGS. 1, 3, 5 to 13, 15 and 16A, 16B, 16C, and a front-back direction in FIGS. 2 and 14 correspond to the radial direction. An upper side in FIGS. 1, 3, 5 to 13, 15 and 16A, 16B, 16C, and a front side in FIGS. 2 and 14 are a radially outer side, and a lower side in FIGS. 1, 3, 5 to 13, 15 and 16A, 16B, 16C, and a back side in FIGS. 2 and 14 are a radially inner side. The rotation-in side refers to a side where the rotor 5 enters the caliper 2 a, and the rotation-out side refers to a side where the rotor 5 exits from the caliper 2 a.

[Caliper]

The caliper 2 a has a substantially bow shape as viewed in the axial direction. The caliper 2 a is fixed to a vehicle body and supports the inner pad 3 a and the outer pad 4 a so as to be movable in the axial direction. The caliper 2 a is disposed so as to cover a part of the rotor 5 in the circumferential direction from the radially outer side, and is supported and fixed to a knuckle constituting a suspension device. The caliper 2 a is molded by casting a material made of light alloy such as aluminum alloy, or iron-based alloy. The caliper 2 a has a split type structure in which an inner side member and an outer side member are coupled by a plurality of bolts 70. The caliper 2 a includes an inner body 6 a, an outer body 7 a, a first coupling portion 8 a, a second coupling portion 9 a and a pair of pins 11 c, 11 d.

The inner body 6 a and the outer body 7 a are disposed on both sides of the rotor 5 in the axial direction so as to sandwich the rotor 5. The inner body 6 a is disposed on an inner side (a center side) in a width direction of the vehicle with respect to the rotor 5, and includes a first inner cylinder 28 a on the one side in the circumferential direction (the right side in FIG. 2, the rotation-in side when moving forward and the rotation-out side when moving reversely), and a second inner cylinder 28 b on the other side in the circumferential direction (the left side in FIG. 2, the rotation-out side when moving forward and the rotation-in side when moving reversely). The inner body 6 a includes a pair of attachment portions 76 for fixing the inner body 6 to the vehicle body, at a radially inner side portion. The outer body 7 a is disposed on an outer side in the width direction of the vehicle with respect to the rotor 5, and includes a first outer cylinder 29 a on the one side in the circumferential direction and a second outer cylinder 29 b on the other side in the circumferential direction.

The first inner cylinder 28 a and the first outer cylinder 29 a are coaxially disposed so as to face each other in the axial direction, and the second inner cylinder 28 b and the second outer cylinder 29 b are coaxially disposed so as to face each other in the axial direction. The first inner cylinder 28 a and the second inner cylinder 28 b communicate with each other through an oil passage (not shown) provided inside the inner body 6 a. The first outer cylinder 29 a and the second outer cylinder 29 b communicate with each other through an oil passage (not shown) provided inside the outer body 7 a. A piston (not shown) is fitted to each of the four cylinders 28 a, 28 b, 29 a, 29 b so as to be displaceable in the axial direction.

As shown in FIG. 5, a pair of overhanging wall portions 12 c, 12 d overhanging in the axial direction so as to approach the rotor 5 are respectively provided on both side portions of an axially inner side surface of the inner body 6 a in the circumferential direction and on both side portions of an axially inner side surface of the outer body 7 in the circumferential direction.

A first torque receiving surface 30 having a flat surface shape is provided on a side surface of the overhanging wall portion 12 c disposed on the one side in the circumferential direction, at a radially inner side portion on the other side in the circumferential direction. A second torque receiving surface 32 having a flat surface shape is provided on a side surface of the overhanging wall portion 12 d disposed on the other side in the circumferential direction, at a radially inner side portion on the one side in the circumferential direction.

Each of the first coupling portion 8 a and the second coupling portion 9 a is disposed on the radially outer side of the rotor 5, and couples end portions of the inner body 6 a and the outer body 7 in the circumferential direction to each other in the axial direction. The first coupling portion 8 a couples the end portions of the inner body 6 a and the outer body 7 a on the one side in the circumferential direction to each other in the axial direction, and the second coupling portion 9 a connects the end portions of the inner body 6 a and the outer body 7 a on the other side in the circumferential direction to each other in the axial direction. The first coupling portion 8 a and the second coupling portion 9 a are each curved in an arc shape along an outer peripheral edge of the rotor 5, and cover the rotor 5 from outside in the radial direction via a predetermined gap.

A first moment bearing surface 31 having a flat surface shape is provided on a side surface of the first coupling portion 8 a on the other side in the circumferential direction, the side surface of the first coupling portion 8 a being located radially outward than the first torque receiving surface 30. A second moment bearing surface 33 having a flat surface shape is provided on a side surface of the second coupling portion 9 a on the one side in the circumferential direction, the side surface of the second coupling portion 9 a being located radially outward than the second torque receiving surface 32.

Each of the pair of pins 11 c, 11 d has a cylindrical shape. Each of the pair of pins 11 c, 11 d is disposed parallel to a central axis of the rotor 5 on the radially outer side of the rotor 5. End portions of each of the pair of pins 11 c, 11 d in the axial direction are supported by radially outer side portions of the inner body 6 a and the outer body 7 a. Specifically, the end portions of each of the pair of pins 11 c, 11 d in the axial direction are respectively inserted into pin support holes 34 formed in the inner body 6 a and the outer body 7 a (see FIG. 1). Thereby, the pair of pins 11 c, 11 d are bridged between the inner body 6 a and the outer body 7 a.

As shown in FIGS. 2 and 4, a stopper fitting 35 is locked to a portion of an intermediate portion of each of the pins 11 c, 11 d in the axial direction, the portion being located between the inner pad 3 a and the inner body 6 a. Thereby, the end portions of the pins 11 c, 11 d in the axial direction are prevented from coming out of the pin support holes 34 in the axial direction. An outer diameter of each of the pair of pins 11 c, 11 d is slightly smaller than an inner diameter of the pin support hole 34.

[Inner Pad and Outer Pad]

The inner pad 3 a and the outer pad 4 a are disposed on both sides of the rotor 5 in the axial direction. Specifically, the inner pad 3 a is disposed between the rotor 5 and the inner body 6 a, and the outer pad 4 a is disposed between the rotor 5 and the outer body 7 a. Each of the inner pad 3 a and the outer pad 4 a includes a lining (a friction material) 36 and a metal back plate (a pressure plate) 37 supporting a back surface of the lining 36. In the present embodiment, the inner pad 3 a and the outer pad 4 a are the same components having the same shape and the same size. Therefore, the following description of details of each part will be focused only on the inner pad 3 a.

As shown in FIG. 9, each of the lining 36 and the back plate 37 constituting the inner pad 3 a has a line-symmetric shape with respect to a symmetry axis a passing through a central portion in the circumferential direction. Therefore, each of the lining 36 and the back plate 37 has the same shape at one side portion in the circumferential direction and the other side portion in the circumferential direction.

On a side surface of the back plate 37 on the one side in the circumferential direction, a first torque transmission surface 38 having a flat surface shape is provided on a radially inner side portion, and a first moment transmission surface 39 having a flat surface shape is provided on a radially outer side portion. The first torque transmission surface 38 is provided on a tip end surface of a radially inner side protruding portion 40 a. The radially inner side protruding portion 40 a is located at a radially inner side portion of the one side portion of the back plate 37 in the circumferential direction, and protrudes to the one side in the circumferential direction from the lining 36. The first moment transmission surface 39 is provided on a tip end surface of a radially outer side protruding portion 41 a. The radially outer side protruding portion 41 a is located at a radially outer side end portion of the one side portion of the back plate 37 in the circumferential direction, and protrudes to the one side in the circumferential direction from the lining 36.

On a side surface of the back plate 37 on the other side in the circumferential direction, a second torque transmission surface 42 having a flat surface shape is provided on a radially inner side portion, and a second moment transmission surface 43 having a flat surface shape is provided on a radially outer side portion. The second torque transmission surface 42 is provided on a tip end surface of a radially inner side protruding portion 40 b. The radially inner side protruding portion 40 b is located at a radially inner side portion of the other side portion of the back plate 37 in the circumferential direction, and protrudes to the other side in the circumferential direction from the lining 36. The second moment transmission surface 43 is provided on a tip end surface of a radially outer side protruding portion 41 b. The radially outer side protruding portion 41 b is located at a radially outer side end portion of the other side portion of the back plate 37 in the circumferential direction, and protrudes to the other side in the circumferential direction from the lining 36.

The back plate 37 includes, at central portion of a radially outer side portion in the circumferential direction, a central protrusion 44 protruding radially outward from portions adjacent to both sides in the circumferential direction. The central protrusion 44 has a substantially rectangular shape. A clip insertion portion 45 penetrating in the axial direction is provided at a substantially central portion of the central protrusion 44 located at the central portion of the radially outer side portion of the back plate 37 in the circumferential direction. The clip insertion portion 45 is a through hole that opens only on both sides of the central protrusion 44 in the axial direction, and has a substantially rectangular shape. The clip insertion portion 45 has a circumferential width dimension larger than a radial width dimension. A pressed surface 46 having a flat surface shape is provided on a radially outer side portion of an inner peripheral surface of the clip insertion portion 45. A locking recess 73 for locking a claw piece 72 of a shim plate 71 disposed on a back side of the back plate 37 (see FIG. 6) is provided in a radially inner side portion of the inner peripheral surface of the clip insertion portion 45.

The back plate 37 includes a pair of shoulder portions 47 a, 47 b protruding radially outward on both side portions of the radially outer side portion in the circumferential direction. The shoulder portion 47 a on the one side in the circumferential direction is connected to the radially outer side protruding portion 41 a on the one side in the circumferential direction, and the shoulder portion 47 b on the other side in the circumferential direction is connected to the radially outer side protruding portion 41 b on the other side in the circumferential direction. In the radially outer side portion of the back plate 37, the shoulder portions 47 a, 47 b located on both sides in the circumferential direction so that the both sides sandwich the clip insertion portion 45, have pin insertion portions 48 a, 48 b penetrating in the axial direction, respectively. Each of the pair of pin insertion portions 48 a, 48 b is a through hole that opens only on both sides of each of the shoulder portions 47 a, 47 b in the axial direction, and has a substantially rectangular shape. Each of the pair of pin insertion portions 48 a, 48 b has a circumferential width dimension larger than a radial width dimension. The radial width dimension and the circumferential width dimension of each of the pair of pin insertion portions 48 a, 48 b are larger than the outer diameter of each of the pins 11 c, 11 d.

The back plate 37 includes a pair of leg portions 49 a, 49 b protruding radially inward on both side portions of a radially inner side portion in the circumferential direction. The leg portion 49 a on the one side in the circumferential direction is connected to the radially inner side protruding portion 40 a on the one side in the circumferential direction, and the leg portion 49 b on the other side in the circumferential direction is connected to the radially inner side protruding portion 40 b on the other side in the circumferential direction. A side surface, of the leg portion 49 a on the one side in the circumferential direction, on the one side in the circumferential direction has a flat surface shape, and is located on the other side in the circumferential direction with respect to the first torque transmission surface 38 provided on the tip end surface of the radially inner side protruding portion 40 a. A side surface, of the leg portion 49 b on the other side in the circumferential direction, on the other side in the circumferential direction has a flat surface shape, and is located on the one side in the circumferential direction with respect to the second torque transmission surface 42 provided on the tip end surface of the radially inner side protruding portion 40 b. As shown in FIG. 12B, a positioning recess 74 having a substantially rectangular shape recessed in the axial direction is provided on a back surface of each of the pair of leg portions 49 a, 49 b. A convex portion (a dowel) 50 protruding in the axial direction is provided at a substantially central portion of the positioning recess 74.

Each of the inner pad 3 a and the outer pad 4 a further includes a pair of circumferential clips 51 a, 51 b. The pair of circumferential clips 51 a, 51 b are fixed to both side portions of the back plate 37 in the circumferential direction. Specifically, the circumferential clips 51 a, 51 b are fixed to the leg portions 49 a, 49 b, respectively.

Each of the circumferential clips 51 a, 51 b is made of a metal plate and includes a main body portion 52 bent in a substantially U shape and an attachment plate portion 53 having a substantially flat plate shape.

The main body portion 52 includes a bent portion 54 having a partially cylindrical shape and a pair of pressing arm portions 55 a, 55 b connected to the bent portion 54. In the pair of pressing arm portions 55 a, 55 b, one pressing arm portion 55 a is formed in a flat plate shape, whereas the other pressing arm portion 55 b has a contact portion 56 bulging in a partially spherical shape at a portion close to a tip end. The attachment plate portion 53 extends in a substantially right angle direction from a tip end portion of the one pressing arm portion 55 a.

The circumferential clip 51 a is fixed to the leg portion 49 a in a state where the main body portion 52 is disposed in a space located on the one side in the circumferential direction of the leg portion 49 a on the one side in the circumferential direction and on the radially inner side of the radially inner side protruding portion 40 a. Specifically, the attachment plate portion 53 is fixed to the back surface of the leg portion 49 a by disposing the attachment plate portion 53 in the positioning recess 74 provided on the back surface of the leg portion 49 a, inserting the convex portion 50 into a through hole 57 provided in the attachment plate portion 53, and caulking and deforming a tip end portion of the convex portion 50.

The circumferential clip 51 b is fixed to the leg portion 49 b in a state where the main body portion 52 is disposed in a space located on the other side in the circumferential direction of the leg portion 49 b on the other side in the circumferential direction and on the radially inner side of the radially inner side protruding portion 40 b. Specifically, the attachment plate portion 53 is fixed to the back surface of the leg portion 49 b by disposing the attachment plate portion 53 in the positioning recess 74 provided on the back surface of the leg portion 49 b, inserting the convex portion 50 into the through hole 57 provided in the attachment plate portion 53, and caulking and deforming the tip end portion of the convex portion 50.

When the circumferential clips 51 a, 51 b are fixed to the back plate 37, the respective bent portions 54 are located radially inward than a radially inner end edge of the back plate 37, and the respective contact portions 56 are located slightly radially inward than a radially inner end edge of the lining 36.

[Pad Support Structure]

The inner pad 3 a and the outer pad 4 a are supported by the caliper 2 a so as to be movable in the axial direction by using the pair of pins 11 c, 11 d. Therefore, in the pair of pin insertion portions 48 a, 48 b provided in the back plate 37, the pin 11 c disposed on the one side in the circumferential direction is inserted in the axial direction into the pin insertion portion 48 a disposed on the one side in the circumferential direction, and the pin 11 d disposed on the other side in the circumferential direction is inserted in the axial direction into the pin insertion portion 48 b disposed on the other side in the circumferential direction.

As shown in FIG. 5, when the inner pad 3 a and the outer pad 4 a are suspended from the caliper 2 a, the first torque transmission surface 38 and the first moment transmission surface 39 provided on the side surface of the back plate 37 on the one side in the circumferential direction respectively face, in the circumferential direction, the first torque receiving surface 30 provided on the overhanging wall portion 12 c on the one side in the circumferential direction and the first moment bearing surface 31 provided on the first coupling portion 8 a. The second torque transmission surface 42 and the second moment transmission surface 43 provided on the side surface of the back plate 37 on the other side in the circumferential direction respectively face, in the circumferential direction, the second torque receiving surface 32 provided on the overhanging wall portion 12 d on the other side in the circumferential direction and the second moment bearing surface 33 provided on the second coupling portion 9 a.

When the inner pad 3 a and the outer pad 4 a are suspended from the caliper 2 a, each of the pair of circumferential clips 51 a, 51 b is elastically deformed between each of the inner pad 3 a and the outer pad 4 a and the caliper 2 a.

As shown in FIG. 8, the circumferential clip 51 a on the one side in the circumferential direction is elastically deformed between the side surface, of the leg portion 49 a provided in the back plate 37, on the one side in the circumferential direction, and the side surface (the first torque receiving surface 30), of the overhanging wall portion 12 c provided in the caliper 2 a, on the other side in the circumferential direction. The circumferential clip 51 a presses each of the inner pad 3 a and the outer pad 4 a and the caliper 2 a in directions opposite to each other in the circumferential direction. Specifically, the circumferential clip 51 a presses radially inner side portions of the side surface of the leg portion 49 a in the circumferential direction and the side surface of the overhanging wall portion 12 c on the other side in the circumferential direction, the portions being slightly radially inward than the radially inner end edge of the lining 36, where the contact portion 56 is located.

The circumferential clip 51 b on the other side in the circumferential direction is elastically deformed between the side surface, of the leg portion 49 b provided in the back plate 37, on the other side in the circumferential direction, and the side surface (the second torque receiving surface 32), of the overhanging wall portion 12 d provided in the caliper 2 a, on the one side in the circumferential direction. Then, each of the inner pad 3 a and the outer pad 4 a and the caliper 2 a are pressed in directions opposite to each other in the circumferential direction. Specifically, the circumferential clip 51 b presses radially inner side portions of the side surface of the leg portion 49 b in the circumferential direction and the side surface of the overhanging wall portion 12 d on the one side in the circumferential direction, the portions being slightly radially inward than the radially inner end edge of the lining 36, where the contact portion 56 is located.

The circumferential clip 51 a disposed on the one side in the circumferential direction presses a radially inner side portion of each of the inner pad 3 a and the outer pad 4 a toward the other side in the circumferential direction. In contrast, the circumferential clip 51 b disposed on the other side in the circumferential direction presses the radially inner side portion of each of the inner pad 3 a and the outer pad 4 a toward the one side in the circumferential direction. Since pressing forces of the pair of circumferential clips 51 a, 51 b are equal to each other, each of the inner pad 3 a and the outer pad 4 a is elastically held (centered) at a neutral position in the circumferential direction.

[Pad Clip]

The pad clip 20 a is a component for preventing occurrence of a brake noise during light braking in which brake fluid has a low hydraulic pressure. The pad clip 20 a is made of a metal plate having elasticity and corrosion resistance such as a stainless steel plate, and has a substantially cross shape as viewed in the radial direction (in a plan view) (see FIGS. 2 and 14).

The pad clip 20 a is integrally formed as a whole, and includes a substrate portion 58 extending in the axial direction, and a pair of circumferential arm portions 59 a, 59 b extending in directions away from each other in the circumferential direction from an intermediate portion of the substrate portion 58 in the axial direction.

As shown in FIG. 2, in a mounted state of the pad clip 20 a, the substrate portion 58 is disposed between the pair of pins 11 c, 11 d in the circumferential direction and on the radially outer side of the rotor 5. The substrate portion 58 has a chevron-shaped cross section that is convex on a radially outer side. The cross-sectional shape of the substrate portion 58 is constant in the axial direction. The substrate portion 58 includes a pad pressing portion 60 a that is inserted into the clip insertion portion 45 of the inner pad 3 a in the axial direction at an end portion on one side in the axial direction, and includes a pad pressing portion 60 b that is inserted into the clip insertion portion 45 of the outer pad 4 a in the axial direction at an end portion on the other side in the axial direction. That is, the substrate portion 58 includes the pair of pad pressing portions 60 a, 60 b disposed at both end portions in the axial direction. As shown in FIG. 6, each of the pair of pad pressing portions 60 a, 60 b has a pressing surface 61 having a flat surface shape, which is in surface contact with the pressed surface 46 constituting the inner peripheral surface of the clip insertion portion 45, on a radially outer side end surface.

As shown in FIG. 2, in the mounted state of the pad clip 20 a, each of the pair of circumferential arm portions 59 a, 59 b is disposed between the inner pad 3 a and the outer pad 4 a and on the radially outer side of the rotor 5. As shown in FIG. 13, each of the pair of circumferential arm portions 59 a, 59 b has a corrugated shape undulating in the radial direction (a plate thickness direction). The pair of circumferential arm portions 59 a, 59 b respectively include first curved portions 62 a, 62 b, second curved portions 63 a, 63 b, third curved portions 64 a, 64 b, pin pressing portions 65 a, 65 b, and tip end plate portions 66 a, 66 b in this order from the substrate portion 58.

Each of the first curved portions 62 a, 62 b is located at a base end portion of each of the circumferential arm portions 59 a, 59 b, and is connected to an intermediate portion of the substrate portion 58 in the axial direction. The first curved portions 62 a, 62 b are curved so as to be convex on a radially inner side. Each of the first curved portions 62 a, 62 b is a tapered portion whose axial width decreases toward a tip end side in the circumferential direction.

Each of the second curved portions 63 a, 63 b is located at an intermediate portion of each of the circumferential arm portions 59 a, 59 b. The second curved portions 63 a, 63 b are curved so as to be convex on the radially outer side. In a free state of the pad clip 20 a, a radially outer side end portion of each of the second curved portions 63 a, 63 b is located radially outward than the pressing surface 61 of each of the pad pressing portions 60 a, 60 b.

Each of the third curved portions 64 a, 64 b is located at the intermediate portion of each of the circumferential arm portions 59 a, 59 b. The third curved portions 64 a, 64 b are curved so as to be convex on the radially inner side. A radially inner side end portion of each of the third curved portions 64 a, 64 b is located on the radially innermost side of the pad clip 20 a. In the free state of the pad clip 20 a, a circumferential interval H64 between side surfaces of the pair of third curved portions 64 a, 64 b on sides far from each other in the circumferential direction (see FIG. 13) is slightly larger than a circumferential interval H11 between end portions of the pair of pins 11 c, 11 d on sides close to each other in the circumferential direction (see FIG. 7) (H64>H11).

Each of the pin pressing portions 65 a, 65 b is located at a portion near a tip end portion of each of the circumferential arm portions 59 a, 59 b. Each of the pin pressing portions 65 a, 65 b has a semi-cylindrical shape that is curved so as to be convex on the radially outer side. Each of the pin pressing portions 65 a, 65 b has a radius of curvature slightly larger than half the outer diameter of each of the pins 11 c, 11 d. A radially outer side end portion of each of the pin pressing portions 65 a, 65 b is located in the radial direction between a radially inner side end portion of each of the first curved portions 62 a, 62 b and a radially outer side end portion of each of the second curved portions 63 a, 63 b.

The tip end plate portions 66 a, 66 b are located at the tip end portions of the circumferential arm portions 59 a, 59 b, respectively. Each of the tip end plate portions 66 a, 66 b is formed in a flat plate shape.

In the mounted state, the pad clip 20 a is elastically deformed between the inner pad 3 a and the outer pad 4 a, and the pair of pins 11 c, 11 d. Specifically, in the pad clip 20 a, in the mounted state, the pair of pad pressing portions 60 a, 60 b provided at end portions of the substrate portion 58 on both sides in the axial direction are respectively inserted in the axial direction into the clip insertion portions 45 provided in the inner pad 3 a and the outer pad 4 a, and the pair of pin pressing portions 65 a, 65 b are respectively locked to the pair of pins 11 c, 11 d from the radially outer side. In this state, the pair of circumferential arm portions 59 a, 59 b are bent and deformed in the radial direction.

Therefore, the pad clip 20 a presses the inner pad 3 a and the outer pad 4 a radially outward by the pair of pad pressing portions 60 a, 60 b, and presses the pair of pins 11 c, 11 d radially inward by the pair of pin pressing portions 65 a, 65 b. That is, the pad clip 20 a applies pressing forces radially outward to the inner pad 3 a and the outer pad 4 a by using the pair of pins 11 c, 11 d as anchors (supporting reaction forces by the pins 11 c, 11 d). Thereby, as shown in FIG. 7, a radially inner side portion of an inner peripheral surface of each of the pair of pin insertion portions 48 a, 48 b is pressed against a radially inner side end portion of each of the pair of pins 11 c, 11 d. The radially inner side portion of the inner peripheral surface of each of the pair of the pin insertion portions 48 a, 48 b is a portion of the inner peripheral surface of each of the pair of the pin insertion portions 48 a, 48 b in the radially inner side of the rotor 5. The radially inner side end portion of each of the pair of the pins 11 c, 11 d is an end portion of each of the pair of the pins 11 c, 11 d in the radially inner side the rotor 5. Therefore, a gap is formed between a radially outer side portion of the inner peripheral surface of each of the pair of pin insertion portions 48 a, 48 b and a radially outer side end portion of each of the pair of pins 11 c, 11 d.

As shown in FIG. 6, the pressing surface 61 provided in each of the pair of pad pressing portions 60 a, 60 b is in surface contact with the pressed surface 46 of the clip insertion portion 45 provided in each of the inner pad 3 a and the outer pad 4 a.

The pair of pin pressing portions 65 a, 65 b further press the pair of pins 11 c, 11 d in directions opposite to each other in the circumferential direction. That is, the pin pressing portion 65 a on the one side in the circumferential direction presses the pin 11 c on the one side in the circumferential direction toward the one side in the circumferential direction, and the pin pressing portion 65 b on the other side in the circumferential direction presses the pin 11 d on the other side in the circumferential direction toward the other side in the circumferential direction. Thereby, the pin 11 c on the one side in the circumferential direction is pressed against one side portion in the circumferential direction of an inner circumferential surface of the pin support hole 34 on the one side in the circumferential direction, and the pin 11 d on the other side in the circumferential direction is pressed against the other side portion in the circumferential direction of the inner circumferential surface of the pin support hole 34 on the other side in the circumferential direction.

Next, assembly work of the disc brake device 1 a will be described with reference to FIGS. 16A, 16B, 16C.

First, as shown in FIG. 16A, in a state before the inner pad 3 a and the outer pad 4 a are assembled into the caliper 2 a, the pair of pad pressing portions 60 a, 60 b provided in the pad clip 20 a are respectively inserted into the clip insertion portions 45 of the inner pad 3 a and the outer pad 4 a to obtain a pad assembly 75 including the pad clip 20 a, the inner pad 3 a and the outer pad 4 a.

Next, the pad assembly 75 is assembled from the radially outer side into a portion between the inner body 6 a and the outer body 7 a constituting the caliper 2 a. Then, as shown in FIG. 16B, the inner pad 3 a and the outer pad 4 a are suspended from the caliper 2 a by one pin 11 c (11 d) of the pair of pins 11 c, 11 d. That is, the one pin 11 c (11 d) is inserted in the axial direction into one pin support hole 34 provided in each of the inner body 6 a and the outer body 7 a and one pin insertion portion 48 a (48 b) provided in each of the inner pad 3 a and the outer pad 4 a. Then, one pin pressing portion 65 a (65 b) provided in the pad clip 20 a is locked to the one pin 11 c (11 d) from the radially outer side.

Next, in the pair of circumferential arm portions 59 a, 59 b, the other circumferential arm portion 59 b (59 a) provided with the other pin pressing portion 65 b (65 a) is pulled up (bent and deformed) radially outward while gripping the tip end plate portion 66 b (66 a). In this state, the other pin 11 d (11 c) is inserted in the axial direction into the other pin support hole 34 provided in each of the inner body 6 a and the outer body 7 a and the other pin insertion portion 48 b (48 a) provided in each of the inner pad 3 a and the outer pad 4 a.

Thereafter, a force gripping the other circumferential arm portion 59 b (59 a) is released, and the other circumferential arm portion 59 b (59 a) is elastically restored. Here, in the free state of the pad clip 20 a, the circumferential interval H64 between the side surfaces of the pair of third curved portions 64 a, 64 b on the sides far from each other in the circumferential direction is set to be slightly larger than the circumferential interval H11 between the end portions of the pair of pins 11 c, 11 d on the sides close to each other in the circumferential direction. Therefore, as shown in FIG. 16C, a radially inner side portion of the third curved portion 64 b (64 a) provided on the other circumferential arm portion 59 b (59 a) comes into abutting (rides on) a radially outer side portion of the other pin 11 d (11 c). Therefore, by further pushing the other circumferential arm portion 59 b (59 a) radially inward, in the other circumferential arm portion 59 a (59 b), the other pin pressing portion 65 b (65 a) is locked to the other pin 11 d (11 c) from the radially outer side while mainly elastically deforming the third curved portion 64 b (64 a) in the circumferential direction.

In the present embodiment as described above, while the other circumferential arm portion 59 a (59 b) is elastically deformed in the circumferential direction, the other circumferential arm portion 59 b (59 a) is pushed inward, so that a radially inner side surface of the other pin pressing portion 65 b (65 a) comes into abutting the radially outer side portion of the other pin 11 d (11 c) with some force. Therefore, a worker who performs the assembly work of the disc brake device 1 a can easily know that mounting work of the pad clip 20 a is correctly performed by a tactile sense (a click feeling) of a finger pushing the other circumferential arm portion 59 b (59 a) inward and a sound (a snap sound) caused by abutting.

In the disc brake device 1 a according to the present embodiment, during braking, the brake fluid is fed from a master cylinder to the first inner cylinder 28 a and the second inner cylinder 28 b provided in the inner body 6 a and the first outer cylinder 29 a and the second outer cylinder 29 b provided in the outer body 7 a. Thereby, the piston (not shown) provided in each of the inner body 6 a and the outer body 7 a is pushed out in the axial direction, and the inner pad 3 a and the outer pad 4 a are pressed against both side surfaces of the rotor 5 in the axial direction. As a result, the rotor 5 is strongly sandwiched by the inner pad 3 a and the outer pad 4 a from both sides in the axial direction, and the vehicle is braked.

The disc brake device 1 a according to the present embodiment generates the following moment in each of the inner pad 3 a and the outer pad 4 a at during braking.

[Moment Acting During Braking]

During forward braking, as shown in FIG. 5, a brake tangential force F1 directed to the other side in the circumferential direction (the left side in FIG. 5 and the rotation-out side when moving forward) acts on a point A at a friction surface center of the lining 36 of the inner pad 3 a (the outer pad 4 a). Thereby, the second torque transmission surface 42 disposed on the other side in the circumferential direction comes into abutting the second torque receiving surface 32 to support the brake tangential force F1. Here, an abutting portion between the second torque transmission surface 42 and the second torque receiving surface 32 is located radially inward than the point A at the friction surface center on which the brake tangential force F1 acts. Therefore, during forward braking, a moment M1 acts on the inner pad 3 a and the outer pad 4 a in a direction in which one side portion in the circumferential direction, which is a rotation-in side portion when moving forward, is pushed up toward the radially outer side, and the other side portion in the circumferential direction, which is a rotation-out side portion when moving forward, is pushed down toward the radially inner side.

The moment M1 is supported by rotating the inner pad 3 a (the outer pad 4 a) counterclockwise and bringing the second moment transmission surface 43 disposed on the other side in the circumferential direction into abutting the second moment bearing surface 33. That is, during forward braking, a posture of each of the inner pad 3 a and the outer pad 4 a is restrained at two portions by the abutting portion between the second torque transmission surface 42 and the second torque receiving surface 32 and an abutting portion between the second moment transmission surface 43 and the second moment bearing surface 33. The point A at the friction surface center is a centroid of a friction surface, and is determined by a diameter, arrangement and the like of the piston.

During reverse braking, a brake tangential force F2 directed to the one side in the circumferential direction (the right side in FIG. 5 and the rotation-out side when moving reversely) acts on the point A at the friction surface center of the lining 36 of the inner pad 3 a (the outer pad 4 a). Thereby, the first torque transmission surface 38 disposed on the one side in the circumferential direction comes into abutting the first torque receiving surface 30 to support the brake tangential force F2. Here, an abutting portion between the first torque transmission surface 38 and the first torque receiving surface 30 is located radially inward than the point A at the friction surface center on which the brake tangential force F2 acts. Therefore, during reverse braking, a moment M2 acts on the inner pad 3 a and the outer pad 4 a in a direction in which the other side portion in the circumferential direction, which is a rotation-in side portion when moving reversely, is pushed up toward the radially outer side, and one side portion in the circumferential direction, which is a rotation-out side portion when moving reversely, is pushed down toward the radially inner side.

The moment M2 is supported by rotating the inner pad 3 a (the outer pad 4 a) clockwise and bringing the first moment transmission surface 39 disposed on the one side in the circumferential direction into contact with the first moment bearing surface 31. That is, during reverse braking, the posture of each of the inner pad 3 a and the outer pad 4 a is restrained at two portions by the abutting portion between the first torque transmission surface 38 and the first torque receiving surface 30 and an abutting portion between the first moment transmission surface 39 and the first moment bearing surface 31.

According to the disc brake device 1 a according to the present embodiment as described above, the occurrence of the brake noise can be prevented even during light braking in which the brake fluid has the low hydraulic pressure.

That is, in the present embodiment, the pair of pad pressing portions 60 a, 60 b included in the pad clip 20 a apply the pressing forces radially outward to the inner pad 3 a and the outer pad 4 a, and press the radially inner side portions of the inner peripheral surfaces of the pair of pin insertion portions 48 a, 48 b respectively against the radially inner side end portions of the pair of pins 11 c, 11 d.

Therefore, for example, when light braking is performed during forward traveling, the moment M1 acting on each of the inner pad 3 a and the outer pad 4 a is reduced, but an acting direction of the moment M1 and acting directions of the pressing forces of the pad clip 20 a (the pair of pad pressing portions 60 a, 60 a) can match at the rotation-in side portion when moving forward (the one side portion in the circumferential direction and a right side portion in FIG. 5) of the inner pad 3 a and the outer pad 4 a. Therefore, unlike the related-art structure described above, it is not necessary to rotate each of the inner pad 3 a and the outer pad 4 a counterclockwise against an elastic force of the pad clip. Therefore, each of the inner pad 3 a and the outer pad 4 a can be rotated counterclockwise by the small moment M1 acting on each of the inner pad 3 a and the outer pad 4 a, and the second moment transmission surface 43 can be easily brought into abutting the second moment bearing surface 33. As a result, at the time of light braking during forward traveling, the posture of each of the inner pad 3 a and the outer pad 4 a can be stabilized, and the occurrence of the brake noise can be prevented.

In addition, even when light braking is performed during reverse traveling, the moment M2 acting on each of the inner pad 3 a and the outer pad 4 a is reduced, but an acting direction of the moment M2 and the acting directions of the pressing forces of the pad clip 20 a (the pair of pad pressing portions 60 b, 60 b) can match at the rotation-in side portion when moving reversely (the other side portion in the circumferential direction and a left side portion in FIG. 5) of the inner pad 3 a and the outer pad 4 a. Therefore, unlike the related-art structure described above, it is not necessary to rotate each of the inner pad 3 a and the outer pad 4 a clockwise against the elastic force of the pad clip. Therefore, each of the inner pad 3 a and the outer pad 4 a can be rotated clockwise by the small moment M2 acting on each of the inner pad 3 a and the outer pad 4 a, and the first moment transmission surface 39 can be easily brought into abutting the first moment bearing surface 31. As a result, even at the time of light braking during reverse traveling, the posture of each of the inner pad 3 a and the outer pad 4 a can be stabilized, and the occurrence of the brake noise can be prevented.

In the disc brake device 1 a according to the present embodiment, the pad clip 20 a applies the pressing forces in the directions opposite to each other in the circumferential direction to the pair of pins 11 c, 11 d, whereby the pair of pins 11 c, 11 d are pressed against inner surfaces of the pin support holes 34 respectively provided in the inner body 6 a and the outer body 7 a. Therefore, when each of the inner pad 3 a and the outer pad 4 a is rotated counterclockwise during forward braking, the pin 11 c on the one side in the circumferential direction can be moved radially outward along the inner surface of the pin support hole 34 disposed on the one side in the circumferential direction. In addition, when each of the inner pad 3 a and the outer pad 4 a is rotated clockwise during reverse braking, the pin 11 d on the other side in the circumferential direction can be moved radially outward along the inner surface of the pin support hole 34 disposed on the other side in the circumferential direction. Therefore, during both forward braking and reverse braking, stability of initial contact between outer circumferential surfaces of the pins 11 c, 11 d and inner circumferential surfaces of the pin support holes 34 can be ensured, and occurrence of vibration in the pins 11 c, 11 d can be prevented.

Since the pressing surface 61 provided in the pad pressing portions 60 a, 60 b is a flat surface and the pressed surface 46 provided in the clip insertion portion 45 is a flat surface, a surface pressure of an abutting portion between the pressing surface 61 and the pressed surface 46 can be suppressed. Therefore, wear of the pressing surface 61 and the pressed surface 46 can be suppressed. During braking, the pressed surface 46 can be smoothly displaced in the axial direction with respect to the pressing surface 61.

Since the pair of circumferential arm portions 59 a, 59 b each have the corrugated shape including the first curved portions 62 a, 62 b, the second curved portions 63 a, 63 b, and the third curved portions 64 a, 64 b, the pressing forces (spring loads) by the pair of pad pressing portions 60 a, 60 b can be increased in comparison with a case where the pair of circumferential arm portions 59 a, 59 b both have a flat plate shape in a limited volume. Since each of the first curved portions 62 a, 62 b is the tapered portion whose axial width decreases as being away from the substrate portion 58, the pressing forces by the pair of pad pressing portions 60 a, 60 b can be increased also from this surface.

In the present embodiment, each of the inner pad 3 a and the outer pad 4 a is pressed in the directions opposite to each other in the circumferential direction by the circumferential clips 51 a, 51 b provided on both side portions of each of the inner pad 3 a and the outer pad 4 a in the circumferential direction. Specifically, the circumferential clips 51 a, 51 b press each of the inner pad 3 a and the outer pad 4 a toward a central side in the circumferential direction. Thereby, each of the inner pad 3 a and the outer pad 4 a can be elastically held at the neutral position in the circumferential direction, and a size of a circumferential gap between the first torque transmission surface 38 and the first torque receiving surface 30 and a size of a circumferential gap between the second torque transmission surface 42 and the second torque receiving surface 32 can be prevented from becoming unnecessarily large (can be made substantially equal to each other). Therefore, during forward braking, the second torque transmission surface 42 and the second torque receiving surface 32 can be prevented from vigorously colliding with each other to cause an abnormal noise (a click sound), and during reverse braking, the first torque transmission surface 38 and the first torque receiving surface 30 can be prevented from vigorously colliding with each other to cause an abnormal noise.

Since a radially outer side portion of each of the inner pad 3 a and the outer pad 4 a is suspended by the pair of pins 11 c, 11 d, a radially inner side portion thereof is easily inclined toward the rotor 5 when a braking force is released. However, in the present embodiment, the circumferential clips 51 a, 51 b are sandwiched between the radially inner side portion of each of the inner pad 3 a and the outer pad 4 a and the overhanging wall portions 12 c, 12 d of the caliper 2 a in a state of being elastically deformed. The circumferential clips 51 a, 51 b press portions of the side surfaces of the leg portions 49 a, 49 b in the circumferential direction and the side surfaces of the overhanging wall portions 12 c, 12 d in the circumferential direction, respectively, the portions being located slightly radially inward than the radially inner end edge of the lining 36. Therefore, when the braking force is released, an inclination angle of each of the inner pad 3 a and the outer pad 4 a can be sufficiently reduced. Therefore, dragging of the inner pad 3 a and the outer pad 4 a can be reduced.

Second Embodiment

A second embodiment will be described with reference to FIG. 17. In the present embodiment, the same components as those of the first embodiment are denoted by the same reference numerals as those of the first embodiment, and detailed description thereof will be omitted.

In the present embodiment, a pad clip 20 b has a cross shape as viewed in the radial direction, similarly to a structure according to the first embodiment, but the entire pad clip 20 b is not formed as an integrated structure and includes a long plate-shaped axial member 67 and a long plate-shaped circumferential member 68 separate from the axial member 67.

The axial member 67 is formed of the substrate portion 58, and has the pair of pad pressing portions 60 a, 60 b at both end portions in the axial direction.

The circumferential member 68 includes the pair of circumferential arm portions 59 a, 59 b and a connection base portion 69 that connects base end portions of the circumferential arm portions 59 a, 59 b to each other in the circumferential direction. The connection base portion 69 is disposed on the radially inner side of an intermediate portion of the axial member 67 (the substrate portion 58) in the axial direction, and is caulking-fixed to the axial member 67 by one or a plurality of caulking portions (not shown).

In the present embodiment as described above, the pad clips 20 b is configured by fixing the long plate-shaped axial member 67 and the long plate-shaped circumferential member 68, and thus a plate removal property of a metal plate can be improved as compared with the structure according to the first embodiment. Therefore, a manufacturing cost of the pad clip 20 b can be reduced.

Other configurations and operational effects are the same as those of the first embodiment.

As a modification of the present embodiment, a configuration in which the long plate-shaped axial member and the long plate-shaped circumferential member separate from the axial member are fixed by riveting instead of caulking may be adopted. In this case as well, an effect of reducing the manufacturing cost of the pad clip can be obtained as in a case of adopting caulking fixation.

Third Embodiment

A third embodiment will be described with reference to FIG. 18. In the present embodiment, the same components as those of the first embodiment are denoted by the same reference numerals as those of the first embodiment, and detailed description thereof will be omitted.

In the present embodiment, shapes of a pair of pad pressing portions 60 c, 60 d constituting a pad clip 20 c are different from those in the structure according to the first embodiment.

Each of the pair of pad pressing portions 60 c, 60 d is inclined in a direction radially inward toward a side away from the rotor 5 in the axial direction (both left and right sides in FIG. 18). Thereby, each of the inner pad 3 a and the outer pad 4 a is pressed radially outward by the pair of pad pressing portions 60 c, 60 d, and is pressed in a direction away from the rotor 5 in the axial direction.

In the present embodiment as described above, when a braking force is released, each of the inner pad 3 a and the outer pad 4 a can be separated from the rotor 5 in the axial direction by the pad pressing portions 60 c, 60 d. Therefore, dragging of the inner pad 3 a and the outer pad 4 a can be reduced. Other configurations and operational effects are the same as those of the first embodiment.

Although the embodiments of the present invention have been described above, the present invention is not limited thereto, and can be appropriately changed without departing from the technical idea of the present invention. In addition, the structures of the embodiments can be appropriately combined and implemented as long as no contradiction occurs.

When the present invention is applied to an opposed piston type disc brake device, the caliper serving as the pad support member is not limited to the split type structure as described in the embodiment, and an integrated type structure (a monocoque structure) can be adopted. The disc brake device according to the present invention is not limited to the opposed piston type disc brake device as described in each embodiment, and can also be applied to a floating caliper type disc brake device. 

What is claimed is:
 1. A disc brake device in which a moment acts on a pad in a direction in which a rotation-in side portion is pushed up toward a radially outer side during braking, the disc brake device comprising: the pad including a pin insertion portion and a clip insertion portion; a pad support member, including a pin inserted into the pin insertion portion in an axial direction, and supporting the pad so that the pad is movable in the axial direction; and a pad clip, including a pad pressing portion inserted into the clip insertion portion in the axial direction, and configured to press the pad radially outward, wherein the pad clip is configured to apply a pressing force to the pad so that a radially inner side portion of an inner peripheral surface of the pin insertion portion is pressed against a radially inner side portion of the pin.
 2. The disc brake device according to claim 1, wherein the pad clip is elastically deformed between the pad and the pin, and applies the pressing force radially outward to the pad.
 3. The disc brake device according to claim 1, wherein the pad support member is a caliper including an inner body and an outer body disposed with a rotor sandwiched between the inner body and the outer body.
 4. The disc brake device according to claim 3, wherein the pad support member includes a torque receiving surface at a radially inner side portion of a rotation-out-side portion and a moment bearing surface at a radially outer side portion of the rotation-out-side portion, the torque receiving surface supports a tangential force acting on the pad during braking, and the moment bearing surface supports the moment acting on the pad in the direction in which the rotation-in-side portion of the pad is pushed up toward the radially outer side during braking.
 5. The disc brake device according to claim 1, comprising: a pair of the pads, wherein the pair of the pads are the same components.
 6. The disc brake device according to claim 1, wherein the pad includes the clip insertion portion at a central portion of a radially outer side portion in a circumferential direction.
 7. The disc brake device according to claim 1, wherein the pad includes a pair of the pin insertion portions on both sides of the radially outer side portion in the circumferential direction so that the both sides sandwich the clip insertion portion, and wherein the pad support member includes a pair of the pins inserted into the pair of pin insertion portions, respectively.
 8. The disc brake device according to claim 7, wherein the pad clip, is made of a metal plate, and includes a substrate portion including the pad pressing portion at an end portion in the axial direction and a pair of circumferential arm portions extending from the substrate portion in directions away from each other in the circumferential direction, and wherein each of the pair of the circumferential arm portions includes a pin pressing portion, disposed on a radially outer side of the pin, and configured to press the pin radially inward.
 9. The disc brake device according to claim 8, wherein the pad clip further presses the pair of pins in directions opposite to each other in the circumferential direction.
 10. The disc brake device according to claim 8, wherein the circumferential arm portion has a corrugated shape undulating in a radial direction.
 11. The disc brake device according to claim 10, wherein the circumferential arm portion includes, between the substrate portion and the pin pressing portion, a first curved portion curved so as to be convex on a radially inner side, a second curved portion curved so as to be convex on a radially outer side, and a third curved portion curved so as to be convex on a radially inner side, in order of closest to the substrate portion.
 12. The disc brake device according to claim 11, wherein in a free state of the pad clip, a circumferential interval between side surfaces of the pair of the third curved portions on sides far from each other in the circumferential direction is larger than a circumferential interval between end portions of the pair of pins on sides close to each other in the circumferential direction.
 13. The disc brake device according to claim 8, wherein the circumferential arm portion further includes a tapered portion whose axial width decreases as being away from the substrate portion in the circumferential direction.
 14. The disc brake device according to claim 8, comprising: the pair of pads, wherein the pad clip has a cross shape as viewed in the radial direction, and wherein the substrate portion includes a pair of the pad pressing portions disposed at the end portions on both sides in the axial direction and respectively inserted into the clip insertion portions provided in the pair of pads.
 15. The disc brake device according to claim 14, wherein the pad clip includes, an axial member including the substrate portion and extending in the axial direction, and a circumferential member being formed separately from the axial member, including the pair of the circumferential arm portions and extending in the circumferential direction.
 16. The disc brake device according to claim 15, wherein the axial member and the circumferential member are fixed by caulking or riveting.
 17. The disc brake device according to claim 1, wherein the pad pressing portion includes, on a radially outer side end surface, a flat surface-shaped pressing surface configured to be in surface contact with a radially outer side portion in an inner peripheral surface of the clip insertion portion.
 18. The disc brake device according to claim 1, wherein the pad pressing portion, is inclined in a direction radially inward as being away from the rotor in the axial direction, and presses the pad radially outward and in a direction away from the rotor in the axial direction.
 19. The disc brake device according to claim 1, further comprising: a circumferential clip configured, to be elastically deformed between the pad and the pad support member, and to press the pad and the pad support member in directions opposite to each other in the circumferential direction.
 20. The disc brake device according to claim 19, comprising: a pair of the circumferential clips, wherein one circumferential clip presses the pad toward one side in the circumferential direction, and the other circumferential clip presses the pad toward the other side in the circumferential direction.
 21. The disc brake device according to claim 19, wherein the circumferential clip presses a radially inner side portion of the pad.
 22. The disc brake device according to claim 19, wherein the circumferential clip is fixed to the pad.
 23. The disc brake device according to claim 19, wherein the circumferential clip presses portions of the pad and the pad support member, the portions having radial positions being the same as that of a radially inner end edge of a lining included in the pad, or the portions being located radially inward than the radially inner end edge of the lining. 